Machine for packaging flexible articles

ABSTRACT

A machine for packaging flexible articles, e.g. disposable diapers, which includes mechanism for forming a stack containing a predetermined number of articles including devices for moving the stack and pushing it into a suitable container. The machine includes an infeed conveyor section used to convey and compress the articles whereupon they are ultimately delivered into successive slots of a pad wheel. The articles are stripped from the slots and simultaneously formed into stacks containing a predetermined number of articles. A pusher element and a stack controller arm are provided to convey each stack into the pocket of an intermittently rotating stack wheel. The stack wheel moves successive stacks into alignment with a support plate whereupon a transfer pusher moves each successive stack fully onto the support plate. A tamper plate is provided to exert a small amount of compressive force on the stack prior to lateral movement of the stack between the support plate and a ceiling plate which is adjacent the tamper plate. A reciprocating side pusher is used to move the stack laterally into position for ultimate movement into a container. A container wheel is intermittently rotated alongside the support plate. Container supporting nozzles project from one side of the container wheel, there being a container telescoped over each of the nozzles. When a nozzle containing an empty container is moved into contiguous relationship with the article stacks, a container load pusher is actuated to move the stacks into the container whereupon on further indexing of the container wheel, the filled container is removed by a full container pusher.

United States Patent [191 Evans et a].

I MACHINE FOR PACKAGING FLEXIBLE ARTICLES [75] Inventors: Stephen F.Evans, St. Bernard;

Eugene R. Sorensen, Cincinnati, both of Ohio [73] Assignee: The Procter& Gamble Company, Cincinnati, Ohio [22] Filed: Oct. II, 1973 [2|] Appl.No.: 405,366

Related U.S. Application Data [62] Division of Ser. No. 239.!72. March29. l972. Pat.

[52] U.S. Cl. 214/7; 27l/2l4; 93/930 P [51] Int. Cl. B66C 17/06 [58]Field of Search 214/7. 6 BA; 27l/2l3, 2l4. 27l/2l5; 93/93 C, 93 DPPrimary E.t'aminerAllen N. Knowles Attorney, Agent. or FirmFredrick H.Braun; John V. Gorman; Richard C. Witte Apr. 8, 1975 [57] ABSTRACT Amachine for packaging flexible articles, e.g. disposable diapers, whichincludes mechanism for forming a stack containing a predetermined numberof articles including devices for moving the stack and pushing it into asuitable container. The machine includes an infeed conveyor section usedto convey and compress the articles whereupon they are ultimatelydelivered into successive slots of a pad wheel. The articles arestripped from the slots and simultaneously formed into stacks containinga predetermined number of articles. A pusher element and a stackcontroller arm are provided to convey each stack into the pocket of aninter' mittently rotating stack wheel. The stack wheel moves successivestacks into alignment with a support plate whereupon a transfer pushermoves each successive stack fully onto the support plate. A tamper plateis provided to exert a small amount of compressive force on the stackprior to lateral movement of the stack between the support plate and aceiling plate which is adjacent the tamper plate. A reciprocating sidepusher is used to move the stack laterally into position for ultimatemovement into a container. A container wheel is intermittently rotatedalongside the support plate. Container supporting nozzles project fromone side of the container wheel. there being a container telescoped overeach of the nozzles. When a nozzle containing an empty container ismoved into contiguous relationship with the article stacks. a containerload pusher is actuated to move the stacks into the container whereuponon further indexing of the container wheel. the filled container isremoved by a full container pusher.

14 Claims, 9 Drawing Figures FZJENT SHEET l 8f 7 Fig. 4

MACHINE FOR PACKAGING FLEXIBLE ARTICLES This is a division. ofapplication Ser. No. 239.l72. now US. Pat. No. 3.8l0.344 filed Mar. 29.I972 BACKGROUND OF THE INVENTION The present invention relates broadlyto the field of packaging machines. More particularly. it is directed toa machine for packaging articles. especially disposable diapers.

The high speed handling of flexible articles such as disposable diapersis a particularly difficult task because of the physical properties ofthe article being handled. Using disposable diapers as an example. itcan be readily appreciated that they are flexible. compress ible andsomewhat variable in dimension. These. of course. are desirablecharacteristics from the standpoint of the ultimate use of the article.but they are certainly undesirable characteristics when considering highspeed handling and packaging by the use of automatic equipment.

Accordingly. one of the major obstacles for efficient high speedhandling of articles of this character has been the provision ofreliable equipment. There have been prior attempts at providingequipment that will function efficiently and effectively in commercialmanufacturing operations but by and large it has been the experiencethat this phase of the operation has been a primary bottleneck. As anexample of prior art techniques that have been employed to overcome someof the problems in the field. reference is made to US. Pat. No.3.474.592 entitled MACHINE FOR PRODUCING AND PACKAGING DIAPERS whichissued to Hans Hessncr on Oct. 28. I969; U.S. Pat. No. 2.224.606entitled STACKING DEVICE which issued to Edmund N. Neckel on Dec. I0.1940; and US. Pat. No. 3.557.972 entitled MECHANISM FOR THE STACK- INGOF ARTICLES which issued to Charles T. Banks on Jan. 26. l97l.

SUMMARY OF THE INVENTION The nature and substance of the invention willbe more readily appreciated after giving consideration to its major aimsand purposes. The principal objects of the invention are recited in theensuing paragraphs in order to provide a better appreciation of itsimportant aspects prior to describing the details of a preferredembodiment in later portions of this description.

A major object of the invention is the provision of a machine forpackaging flexible articles.

Another object of the invention is the provision of a machine forreceiving. stacking and accumulating a continuous or intermittent supplyof individual articles such as disposable diapers and forming stackscontaining a predetermined number of articles at very high speed.

Still another object of the invention is the provision ofa machine ofthe above character that is highly reliable and capable of operation athigh speeds with virtually no damage to the article being handled.

A further object of the invention is the provision of a machine thatwill effectively handle articles such as disposable diapers and formthem into individual groups which are then re-oriented and loaded into acontainer.

(ill

These and other objects are achieved by providing a machine which iscapable of receiving individual articles into successive slots on theperiphery of a continuously rotating pad wheel. The articles are removedfrom the slots of the wheel by a stripper plate as they contact theupper surface thereof. The articles are accumulated in a stackcontaining a predetermined number of articles. The formed stack is thenpushed into a pocket ofa stack wheel. The stack wheel is indexed andmoved intermittently such that successive stacks can be pushed from thestack wheel onto a support plate. A side pusher is provided to move thestack laterally on the support plate such that one or more stacks are inposition for insertion into a container.

A container wheel is supported for intermittent rotation alongside thesupport plate. Erected and opened cartons or like containers are fed tothe container wheel from a suitable source. The containers are placed intelescoping engagement with a receiving nozzle projected from one sideof the container wheel. there being an opening in the container wheel inalignment with the nozzle. The container wheel is then indexed intoposition to receive the stack or stacks of articles which are insertedthereinto by means of a container load pusher. The filled container issubsequently removed from the container wheel by a full containerpusher.

BRIEF DESCRIPTION OF THE DRAWINGS While the specification concludes withclaims particularly pointing out and distinctly claiming the subjectmatter regarded as forming the present invention. it is believed theinvention will be better understood from the following description takenin connection with the accompanying drawings in which:

FIG. I is a side elevation illustrating the machine of the invention.

FIG. 2 is a plan view of the machine of FIG. 1 with the infeed conveyorportion removed to simplify and facilitate illustration in this view.

FIG. 3 is an enlarged fragmentary elevation taken on the line 3-3 ofFIG. 2 illustrating the pad wheel. tunnel. and stack wheel.

FIG. 4 is an elevation in cross section taken on the line 4-4 of FIG. Iillustrating the support plate and various pusher devices associatedtherewith including the container wheel.

FIG. 5 is a fragmentary side elevation taken on the line 55 of FIG. 4provided primarily to illustrate the details of the tamper plateassociated with the support plate for the purpose of compressing thecompleted stack.

FIG. 6 is another fragmentary side elevation taken on the line 66 ofFIG. 4 which illustrates the pusher elements for moving the stacks intothe containers and for thereafter removing the filled containers fromthe container wheel.

FIG. 7 is a fragmentary view taken on the line 77 of FIG. 3 illustratingthe stripper plate. tunnel and spring loaded gate elements that areinterposed be tween the pad wheel and the stack wheel.

FIG. 8 is a side elevation taken on the line 88 of FIG. 7 illustratingfurther details of the same portion of the device.

FIG. 9 is a perspective view of a disposable diaper that has been foldedin half which is the preferred condition in which the machine of theinvention acts on such articles.

In each of FIGS. 1 to 8 inclusive. some portions or elemcnts of themachine have been simplified or removed to provide for a clearunderstanding of underlying parts or elements. Those skilled in the artwill be aware of these simplifications when considering the severalviews of the machine as a whole.

DESCRIPTION OF THE PREFERRED EMBODIMENT In order to achieve a thoroughunderstanding of the invention. aa description of the preferred type ofarticle for which it is designed seems desirable. It will be understood. however. that the machine is not limited. in a broad sense. tothe handling of any particular type of article. In a preferredembodiment the machine is designed to form stacks of flexible articlesand thereafter move them into a container or carton. The type of articlefor which the machine is adapted may be broadly characterized as a padof the kind typified by any of several well known commercial productssuch as disposable diapers. paper napkins. paper towels. sanitarynapkins or the like. In its preferred form. the machine has beendeveloped to be used in the stacking and packaging of pads such as thedisposable diapers of the type described and claimed in US. Pat. Re.26,15l Duncan et al. issued Jan. 31. 1967, which is commonly owned bythe assignee of the present invention. While the machine will bedescribed in connection with the handling and packaging of disposablediapers. it will be understood that this does not form any limitation onthe scope of the invention or is to imply that the machine is notcapable of handling other kinds of articles having similarcharacteristics.

Referring initially to FIG. 9. there is illustrated a typical disposablediaper [0. this being the preferred form of paid handled by the machine.The diaper I is of the type having box pleats and will be familiar topersons of ordinary skill in the art who will be acquainted with theteachings ofthe aforesaid Duncan et al patent. The box pleats are formedand folded along the side edges of the diaper whereupon the diaper I0 isfolded on itself in the middle portion thereof to form a nose ll afterthe diaper is folded into the configuration illustrated in FIG. 9.Diapers in the form of FIG. 9 are forwarded to the machine of thepresent invention from a final folding mechanism of a diaper convertingmachine. the movement of the diaper 10 being such that the nose II isforemost in its path of movement.

Referring now to FIG. I, the diapers 10 pass between the rolls l2 and I3forming a portion ofthe final folding mechanism of the diaper convertingmachine whereupon they are delivered in single file order to an infeedconveyor illustrated generally at 14. The infeed conveyor 14 consists ofa first section 15 and second section 16. there being a diverter plate17 interposed between the sections 15 and 16. The infeed conveyor 14 issupported by the frame 18 which is used as a rigid support for theseveral mechanisms of the entire machine.

The first section lS of the infeed conveyor 14 comprises a pair ofopposed forwarding belts l9 and suitably supported and driven to receivethe diapers 10 with their nose It foremost and move them forward at aspeed matched with the speed at which they are received from the rollsl2 and 13. The forwarding belts l9 and 20 are backed by the compressionrolls 19a and 20a spaced apart such that the belts l9 and 20 also imparta desired amount of compression to the folded diaper l0. Diapers l0slide over the diverter plate 17 whereupon the nose ll of each diaper isengaged by the entrance nip between the forwarding belts 21 and 22mounted in the second section 16. The belts 21 and 22 forward theindividual diapers 10 for the purpose of feeding them individually tothe pad wheel 23 as will be hereinafter more fully described.

The belts l9 and 20 are directly driven from the pad cycle shaft 24which is turned at an angular speed of one revolution per diaper. Thesource of motive power for rotating the pad cycle shaft 24 may beprovided by an independent power unit or it can be directly coupled tothe diaper converting machine. The shaft 24 drives the belts l9 and 20by the use of a conventional chain and sprocket drive mechanismincluding the right angle gear box 25. The forwarding belts 21 and 22may be driven at matched speed with the belts l9 and 20. However. theyare preferably driven at a slightly slower speed, about 15 per centslower. so that they can prop erly insert the individual diapers intothe pad wheel 23.

The forwarding belts 21 and 22 are also driven from the pad cycle shaft24 by the use of a conventional chain and sprocket drive mechanism whichincludes a variable speed drive 26 and a right angle gear box 27. Thevariable speed drive 26 may be used for fine adjustment of the speed ofthe belts 2] and 22 to permit variation of the insertion speed ofsuccessive diapers into the slots 28 in the pad wheel 23. While theforwarding belts of the second section 16 are preferably driven at asomewhat slower speed than those of the first section 15, this presentsno problem of buckling or puckering of the diapers 10 as they aretransferred across the diverter plate 17 from the first to the secondsection since the distance between the exit nip of the first section 15and the entrance nip of the second section 16 is equal to or slightlyless than the length dimension of the thick absorbent core portion ofthe diaper 10. Thus during transfer. the diaper I0 is fully supported bythe diverter plate 17 as it moves from the first section 15 to thesecond section 16 without any substantial effect on the diaper itself.

The machine includes means for forming a plurality of diapers 10 into astack containing a predetermined number of diapers. This will now bedescribed in reference to FIGS. 1, 2 and 3. As previously indicated, thefunction of the pad wheel 23 is to receive successive diapers ll)delivered in spaced single file order from the infeed conveyor 14. Thepad wheel 23 is mounted for rotation on the frame [8 and is providedwith a plurality of equally spaced arcuate slots 28. The pad wheel 23 isturned continuously by means to be described such that the slots 28 aresequentially aligned with the exit nip of the forwarding belts 21 and22. Thus, successive slots 28 are moved into diaper receiving positionsuch that diapers 10 can be inserted therein. As illustrated in FIG. 2,the pad wheel 23 may comprise a pair of spaced similarly configuredwheel elements 2323 mounted on a common shaft 29 and driven continuouslyby the pad cycle shaft 24 through a conventional chain and sprocketdriven mechanism includ ing the gear box 30.

Means are provided to remove each individual diaper 10 from thesuccessive slots 28 in the pad wheel 23 and thereby form a stack 3]containing a predetermined number of diapers standing on their noses ll.Referring to FIGS. 1, 2, 3, 7 and 8, it will be noted that an obliquelymounted stripper plate 32 is provided such that it intercepts the pathof movement of the slots 28 in the pad wheel 23 (FIG. 7). As aconsequence. the nose ll of each diaper It) strikes the stripper plate32 causing it to slide from the slot 28 as the pad wheel 23 is rotated.The diapers 10 are thereby placed in essentially vertical orientation onthe stripper plate 32 (FIG. 3). As each successive diaper it) isdeposited on the stripper plate 32, the previously deposited diaper ordiapers l0 ofa given stack 31 are moved slightly forward by the trailingedges 33 (FIG. 3) of the pad wheel 23.

Means are provided to hold the diapers in their upright position andprevent twisting thereof as they are removed from the pad wheel 23 toform a stack 31 on the stripper plate 32. Mounted along opposite sidesof the stripper plate 32 in substantially vertical orientation are guideplates 34 and 35 (FIG. 7). A plurality offlexible fingers 36 (FIGS. 7and 8) which may be formed of rubber or like material are mounted suchthat one row is above and another row below the guide plates 34 and 35.The flexible fingers 36 assist in maintaining the individual diapers l0upright until a stack 31 consisting of a predetermined number of diapershas been completed whereupon it is moved forward by a pusher element tobe hereinafter described. The guide plates 34 and 35. together with theflexible fingers 36, combine to form a tunnel 37 which functions as asupport and guide for the individual stack 31 of diapers 10 as they aremoved to the right as viewed in FIGS. 7 and 8. The flexible fingers 36on opposite sides of the tunnel 37 are spaced apart such that theyengage the side edges of the diapers forming the stacks 31. Thismaintains the diapers upright during their insertion in the tunnel 37regardless of whether the diaper supply is continuous or interrupted.

Means are provided for conveying and moving the stack onto a supportplate. As best illustrated in H68. 1 and 3, means for moving the stacks3l is supported by the frame l8 and includes a chain 38 running over theseveral illustrated sprockets (FIG. 3). A plurality of pushing elements39 project outwardly from and are secured to the chain 38. The chain 38is intermittently moved when a completed stack 31 has been formed tomove the stack from the stacking station adjacent the pad wheel 23 bysliding it through the tunnel 37 for the purpose of delivering thecompleted stack to a second station at a pocket of the stack wheel 45.

In examining FIGS. 3 and 7, it will be noted that the individual pusherelements 39 are relatively narrow permitting their movement between thespaced elements 23-23 forming the pad wheel. In addition, a central slot46 is formed in the stripper plate 32 to permit movement of the pushingelements 39 to the stack wheel and beyond. As illustrated in FIG. 3. thestack wheel 45 is mounted for intermittent rotation on the frame [8 andcontains a plurality of pockets 47, each being designed to receive andretain a stack 31 of diapers 10.

An additional mechanism is provided for controlling the completed stack3] and to prevent dislodgement of the leading diaper in the stack whenit is moved from the stacking station to the second station in thepocket 47. This mechanism is illustrated in FIGS. 1 and 3. it comprisesa superstructure 41 supported above the frame 18. A chain 40 isassembled to run over the illustrated sprockets which are journalled andsupported on the superstructure 41. A plurality of stack controller arms42 are sttached to the chain 40 for intermittent movement in acircuitous path. The arms 42 can be pivoted at the pin 43 such that theycan be retracted from and extended into their operative positions duringeach cycle of their movement by the use of conventional cams and camfollowers as will be appreciated by those skilled in the art. The arm 42is pivoted into its extended position after movement of the chain 40such that the pad 44 on the arm 42 will be stopped in posi tion tocontact the foremost diaper in the completed stack 31. The arm 42 ispivoted to its retracted or inactive position after the stack 31 isdelivered to the pocket 47.

The chain 40 moves intermittently in unison with the chain 38. Themovement of the chains 38 and 40 is timed so that a completed stack 31is formed between a pushing element 39 and a stack controller arm 42.Thereupon. the chains 38 and 40 are put in motion so that a cohesivestack 3] is moved and delivered from the stacking station to a secondstation at the pocket 47 without any of the diapers 10 becomingdislodged on otherwise disoriented in the stack.

Referring again to FIGS. 7 and 8. it will be noted that a pair of springloaded side members 48 and 49 are provided at opposite sides of thepocket 47 of the stack Wheel 45. These side members 48 and 49 areprovided to prevent lateral movement of the stack and thereby retain itin the pocket 47. in the inlet portion of the pocket 47 are mounted aplurality of flexible fingers 50 provided to permit entrance of thestack 3] into the pocket 47 with relative ease. The fingers 50 tend topreclude reverse travel and retain the stack in the pocket. Each pocket47 in the stack wheel 45 is provided with a similar pair of springloaded side members 48 and 49 as well as a plurality of flexible fingers50.

The pad wheel 23 is rotated continuously whereas the pushing elements39. the stack controller arms 42 and the stack wheel 45 are moved and/orrotated intermittently inasmuch as their movement is dependent upon theformation of a completed stack 3l before they can move the stack and bein position to receive the next succeeding stack. Referring now to FIGS.1 and 2, the drive for these various elements will now be described.Basically. the pushing elements 39, the stack controller arms 42 and thestack wheel 45 are driven by the stack cycle shaft Sl which receives itspower input from the pad cycle shaft 24. Whereas the pad cycle shaft 24makes one revolution per diaper, the stack cycle shaft 51 makes onerevolution per stack. in order to achieve such synchronization and makeallowance for missing diapers. the drive from the pad cycle shaft 24 tothe stack cycle shaft 51 includes a differential drive element 52 thathas two inputs. The first is a direct input to the shaft 53 by means ofthe chain 54 driven by the pad cycle shaft 24. The second input to thedifferential drive 52 is from the one revolution clutch 55.

The output from the differential drive 52 is directly coupled to thestack cycle shaft Si by means ofthe gear box 56. Ordinarily the padcycle shaft 24 will thereby directly drive the stack cycle shaft 51 atthe proper reduction through the intermediary of the differential drive52. However, in the event of a missing diaper. the one revolution clutch55 is energized by a suitable control (not shown) which is designed fordetecting any missing diapers. The one revolution clutch 55 then exactlycancels the input from the shaft 53 for one revolution and this thenprecludes movement of the stack in formation for an additionalrevolution of the pad cycle shaft 24 so that the predetermined number ofdiapers is deposited in the stack 21. In other words. the differentialdrive 52 is used to provide a variable control whereby each stack formedon the stripper plate 32 will have the same number of diapers therein(usually either twelve or fifteen depending on diaper size).

The chain 38 for moving the pushing elements 39 is driven intermittentlyfrom the stack cycle shaft 51. The drive includes a conventional chainand sprocket drive mechanism from the shaft 51 to a conventionalindexing mechanism 56a (FIG. 2). The output from the indexing mechanism56a is transmitted to a gear box 57 (FIG. 3). The output from the gearbox 57 provides an intermittent drive to the chain 38 through aconventional chain and sprocket drive mechanism as illustrated. Thechain 38 is timed so that it moves a stack 31 through the tunnel 37 uponcompletion of the stack 31.

The chain 40 for moving the stack controller arms 42 is drivenintermittently from the stack cycle shaft 51 so that it movessynchronously with the chain 38. The drive for the chain 40 is notillustrated because it is identical to that used for the chain 38. Thatis. it includes a conventional chain and sprocket drive mechanism fromthe shaft 51 to a conventional indexing mechanism (not shown). theoutput of which is transmitted to a gear box (not shown). The outputfrom the latter gear box is used to intermittently drive the chain 40through the medium of another conventional chain and sprocket drive.

The stack wheel 45 is intermittently indexed and rotated through apredetermined are upon entry of a stack 31 in a pocket 47. The drive forthe stack wheel 45 includes a conventional indexing mechanism 57a drivenfrom the stack cycle shaft 51 by means ofa conventional chain andsprocket drive.

The machine includes mechanism and means for removing the stack 31 fromthe stack wheel 45 and moving it on a support plate 58 whereupon it ismoved into position for insertion into a carton or similar packagingreceptacle. After the pocket 47 containing a stack 31 has been indexedthrough two cycles. it is in position to have the stack 31 removed. Atransfer pusher is provided for this purpose which moves the stack 31onto the support plate 58. Spaced over the support plate 58 andessentially parallel therewith are the stationary ceiling plate 59 andthe oscillating tamper plate 60 (see FIGS. 4 and As seen in FIG. 3. thetransfer pusher includes a pusher head 61 secured to a crosshead 62which is mounted for sliding movement on the rods 63. Movement isimparted to the pusher head 61 by means of the rocker arm 64. theconnecting rod 65 and the crank 66 (FIG. 5). The crank 66 is driventhrough the gear box 67 by a conventional indexing mechanism 68, thelatter being driven by a conventional chain and sprocket drive from thestack cycle shaft 51 (FIGS. 2, 4 and 5). It will be apparent. then. thatat the appropriate time in the cycle. i.e.. when the pocket 47 of thestack wheel 45 has reached the unload position alongside the supportplate 58 (illustrated in FIGS. 1 and 3). that the pusher head 61 will beactuated to push the finished stack 31 out of the pocket 47 and onto thesupport plate 58 as illustrated in FIGS. 1 and 4.

The machine also includes a means for compressing the stack 31 prior toand during the transfer of the stack from the stack wheel 45 by thepusher head 61. Referring again to FIG. 5, it will be noted that thetamper plate 60 is illustrated in its down position to which it is movedafter the stack wheel 45 has been indexed such that a stack 31 is inposition for removal from the stack wheel 45. The tamper plate 60 ismoved to its uppermost position prior to indexing of the stack wheel 45and after the stack 31 has been moved laterally from beneath the tamperplate 60 by means to be hereinafter described. The phantom outline 60'illustrates the uppermost position of the tamper plate 60 which isassumed during indexing of the stack wheel 45.

A four bar linkage mechanism is provided for moving the tamper plate 60.The four bar linkage mechanism includes the links 69 and 70, theconnecting rod 71 and the crank 72. The tamper plate 60 is moved intimed relation to the infeed of new stacks 31 by means of a conventionalair driven rotary actuator 73 which is synchronously operated to achievethe purpose of compressing the new stack at the proper time in the cycleafter delivery onto the support plate 58.

The machine includes means for moving the compressed staek into positionfor insertion into a carton. As best illustrated in FIG. 4, a sidepusher device is provided to push each compressed stack of diapers frombeneath the tamper plate 60 laterally between the sup port plate 58 andthe ceiling plate 59. The lateral movement of the stack clears theinfeed area beneath the tamper plate 60 so that another stack can bemoved from the stack wheel 45 and deposited on the support plate 58. Theside pusher device includes the pusher head 74 which is moved laterallyby the crosshead 75 sliding on the rods 76. The pusher head 74 isactuated by the rocker arm 77 which is oscillated by the connecting rod78, the latter being moved by the crank 79. The crank 79 is driven fromthe gear box 80 (FIG. 2) which in turn is driven from the indexingmechanism 81, the latter being connected through conventional chain andsprocket drive to the stack cycle shaft 51.

The drive mechanism for the pusher head 74 is thus designed to move eachstack of diapers laterally at the appropriate time in the cycle in orderto clear the infeed area of the support plate 58. Another stack isdeposited in the infeed area of the support plate 58 on the next machinecycle. This stack is also pushed laterally clear of the infeed area asthe machine moves through the same cycle used in imparting lateralmovement to the first stack. As the second stack is pushed aside. itcontacts and in turn pushes the first stack. The stacks accumulate asthey are pushed laterally until the first stack contacts the wall 82(FIG. 2) at the end of the support plate 58. In this position. the twostacks nearest the wall 82 are then ready for insertion into acontainer. A short wall 820 is provided (FIGS. 2 and 4) as a guide forthe stacks such that movement of the stacks into the container is guidedby the walls 82 and 820. In the preferred embodiment of the instantdisclosure, the loading of two side-by-side stacks. i.e.. two stacks ora double stack. are described as being loaded into a container. However.it will be apparent to those skilled in the art that with relativelyminor modification, the ma chine can be used to push a single stack intoa container or three stacks or any number of stacks as desired. Themachine can be used to load stacks into a bag, canon or any other kindof container or receptacle as will be understood by those skilled in theart.

Container wheel 83 is illustrated in FIGS. 1, 2, 4 and 6. The containerwheel 83 functions as a preferred means for receiving and holding acontainer. carton or like receptacle in an article receiving attitude.It is supported alongside the support plate 58. The container wheel 83is rotated intermittently. As seen in FIG. 4, the container wheel 83 isprovided with a plurality of openings 84. The axis of the containerwheel 83 is such that when one of the openings 84 is in its lowermostposition, i.e., the 6:00 oclock position in FIG. 4, it is aligned withthe opening formed by the ceiling plate 59, the wall 82, the supportplate 58 and the guide wall 82a. In this position. the double stack ofdiapers can be pushed laterally through the opening 84.

A container receiving nozzle 85 is mounted extend ing from each of theopenings 84 (FIGS. 1, 2 and 6). The outer ends of the nozzles 85 areprovided with spring leaf members to facilitate loading and feeding ofcontainers such as cartons. The nozzles 85 receive and supportindividual containers or cartons 86 which are held in telescopingengagement thereover by the engagement of the carton flaps with springclips 85a. The cartons 86 are fed to the machine with their bottom flapsadhered shut prior to their engagement over the nozzles 85. Cartons 86may be automatically or manually loaded onto each nozzle 85 when theopening 84 is in the 9:00 oclock position as viewed in FIG. 4.

A suitable mechanism is provided for indexing the container wheel 83such that it serves as a preferred means for aligning each container orcarton 86 with successive stacks 31 that have been moved into positionfor insertion into a container. The container wheel 83 is driven fromthe stack cycle shaft 51 by conventional chain and sprocket drivemechanisms through an electric clutch brake 87 (see FIGS. 1 and 2). Acontainer cycle shaft 88 is driven from the electric clutch brake 87 andimparts the drive to the container wheel 83 by means of the conventionalindexing mechanism 89 and the right angle gear box 90, the latter beingdirectly connected to and supporting the container wheel 83. The drivemechanism just described properly indexes and cycles the container wheel83 as each container or carton is filled and removed from the nozzles.

Suitable mechanism and means are provided for pushing the stacks 31 onthe support plate 58 into the containers or cartons 86 andsimultaneously removing a full container from the container wheel 83(FIG. 6). The mechanism for moving the stacks of diapers into thecontainers includes a container load pusher 91 movable laterally by thecrosshead 92 which slides on the rods 93. The crosshead 92 is actuatedby the rocker arm 94 which is oscillated by the connecting rod 95, thelatter being moved by the crank 96, the power input to the crank 96being received from the gear box 97.

A similar mechanism is provided to remove a filled container 86 from thecontainer wheel 83 when it is in the uppermost position or the 12:00oclock position as viewed in FIG. 4. Referring to FIG. 6, this mechanismincludes a full container pusher 98, moved laterally by the cross head99 sliding on the rods 100. Crosshead 99 is moved by the rocker arm 10!which is oscillated by a mechanism including the connecting rod 102 andthe crank I03. Container load pusher 91 and the full container pusher 98are driven from the container cycle shaft 88 through a conventionalchain and sprocket drive from the gear box 104 (FIG. 2), the right anglegear box 105, the indexing mechanism 106 which in turn drives the gearbox 97 which is illustrated in each of FIGS. 2, 4 and 6. The drive fromthe gear box 97 to the full container pusher 98 is by means of aconventional chain and sprocket drive.

While not illustrated in the drawings, the apparatus preferably includesmechanism and means for maintaining a low pressure air cushion betweenthe contacting surfaces of the diapers and the corresponding surfaces ofthe tamper plate 60, ceiling plate 59 and the support plate 58. This ispreferably provided to minimize sticking and thereby prevent diaperdamage and distortion which could occur as the diapers are moved inseveral directions while going through the cycle. This is achieved byproviding the surfaces in question with a series of holes which aresupplied with low pressure air to produce the desired air cushion effectthereby reducing the frictional forces between the pad surfaces and thesupport and ceiling plate surfaces.

It will be apparent to persons skilled in the art that many variationscan be made within the scope of the invention. For example. pad wheelsize, slot size. slot length and the extent the pads are driven into theslots can be varied. The pushing elements 39 and the stack controllerarms 42 which coact to move stacks 3] from the pad wheel 23 to the stackwheel 45 can be actuated by a linkage. air cylinder or other means inlieu of the chains described heretofore. The stack wheel 45 can be madeby any reasonable number of pockets. A variety of different pocketdesigns could be used to contain stacks. The container wheel 83 can bemade with more or less than four nozzles. With minor adjustments in sizechange parts. the double stack operation can be eliminated and a singlestack can be formed and moved into the containers.

While particular embodiments of the invention have been illustrated anddescribed, it will be obvious to those skilled in the art that variouschanges and modifications can be made without departing from the spiritand scope of the invention and it is intended to cover in the appendedclaims all such changes and modifications that are within the scope ofthis invention.

What is claimed is:

l. A mechanism for stacking and moving flexible articles comprising thecombination of:

a. means for forming a plurality of articles into a stack containingpredetermined number of superposed articles.

b. means for holding the articles along their side edges to maintainthem in their upright position and to prevent twisting of the articlesas they are being formed into a stack while simultaneously being removedfrom said stack forming means.

c. means for conveying and moving said stack from a stacking station toa second station. and

d. means for controlling the completed stack during movement by saidconveying and moving means to prevent dislodgement and misalignment ofany articles in said stack during movement. said control ling meansbeing actuated synchronously with said conveying and moving means.

2. A mechanism for stacking and moving flexible articles as claimed inclaim 1 wherein said stack forming means comprises a pad wheel having aplurality of spaced arcuate slots on its periphery, means for depositingarticles into the slots thereof and a stripper plate for intercepting aleading edge of each article while supported in a slot to remove thearticles from said slots and form a stack of superposed articles on saidstripper plate.

3. A mechanism for stacking and moving flexible articles as claimed inclaim 1 wherein said means for conveying and moving said stack comprisesan intermittently moving pushing element for moving a newly formed stackto said second station.

4. A mechanism for stacking and moving flexible arti cles as claimed inclaim 2 wherein said means for conveying and moving said stack comprisesan intermittently moving pushing element for moving a newly formed stackto said second station.

5. A mechanism for stacking and moving flexible articles as claimed inclaim 1 wherein said means for holding the articles along their sideedges comprises a plurality of flexible fingers directed inwardly towardand engaging both side edges of the articles forming the stacks.

6. A mechanism for stacking and moving flexible articles comprising thecombination of:

a. means for continuously conveying articles in single file order.

b. means for receiving successive articles from said conveying means andforming said articles into a stack of superposed articles at a stackingstation.

c. means for holding the articles along their side edges to maintainthem in their upright position and to prevent twisting of the articlesas they are being formed into a stack while simultaneously being removedfrom said stack forming means.

d. means for removing said stack from said stacking station after thestack contains a predetermined number of articles.

e. said removing means including means for conveying and moving saidstack of articles from the stacking station to a second station.

7. A mechanism for stacking and moving flexible articles as claimed inclaim 6 wherein said means for receiving successive articles and formingsaid articles into a stack comprises a pad wheel having a plurality ofspaced arcuate slots on its periphery. means for depositing articlesinto the slots thereof and a stripper plate for intercepting a leadingedge of each article while supported in a slot to remove the articlesfrom said slots and form a stack of superposed articles on said stripperplate.

8. A mechanism for stacking and moving flexible articles as claimed inclaim 6 wherein said means for conveying and moving said stack comprisesan intermittently moving pushing element for moving a newly formed stackto said second station.

9. A mechanism for stacking and moving flexible articles as claimed inclaim 7 wherein said means for conveying and moving said stack comprisesan intermittently moving pushing element for moving a newly formed stackto said second station.

10. A mechanism for stacking and moving flexible articles as claimed inclaim 6 wherein said means for holding the articles along their sideedges comprises a plurality of flexible fingers directed inwardly towardand engaging both side edges of the articles forming the stacks.

11. A mechanism for stacking and moving flexible articles comprising thecombination of:

a. means for forming a plurality of articles into a stack containing apredetermined number of superposed articles,

b. means for conveying and moving said stack from a stacking station toa second station, and

c. means for controlling the completed stack during movement by saidconveying and moving means to prevent dislodgement and misalignment ofany articles in said stack during movement. said controlling means beingactuated synchronously with said conveying and moving means. saidcontrolling means comprising an intermittently moving stack controllerarm having a forwardly projecting pad for engaging the foremost articlein the stack during movement thereof to said second station therebypreventing dislodgement and misalighment of any articles in said stackduring movement thereof.

12. A mechanism for stacking and moving flexible articles as claimed inclaim 11 wherein said stack forming means comprises a pad wheel having aplurality of spaced arcuate slots on its periphery. means for depositingarticles into the slots thereof and a stripper plate for intercepting aleading edge of each article while supported in a slot to remove thearticles from said slots and form a stack of superposed articles on saidstripper plate.

13. A mechanism for stacking and moving flexible articles as claimed inclaim 11 wherein said means for conveying and moving said stackcomprises an intermittently moving pushing element for moving a newlyformed stack to said second station.

14. A mechanism for stacking and moving flexible articles as claimed inclaim l2 wherein said means for conveying and moving said stackcomprises an intermittently moving pushing element for moving a newlyformed stack to said second station.

1. A mechanism for stacking and moving flexible articles comprising thecombination of: a. means for forming a plurality of articles into astack containing predetermined number of superposed articles, b. meansfor holding the articles along their side edges to maintain them intheir upright position and to prevent twisting of the articles as theyare being formed into a stack while simultaneously being removed fromsaid stack forming means, c. means for conveying and moving said stackfrom a stacking station to a second station, and d. means forcontrolling the completed stack during movement by said conveying andmoving means to prevent dislodgement and misalignment of any articles insaid stack during movement, said controlling means being actuatedsynchronously with said conveying and moving means.
 2. A mechanism forstacking and moving flexible articles as claimed in claim 1 wherein saidstack forming means comprises a pad wheel having a plurality of spacedarcuate slots on its periphery, means for depositing articles into theslots thereof and a stripper plate for intercepting a leading edge ofeach article while supported in a slot to remove the articles from saidslots and form a stack of superposed articles on said stripper plate. 3.A mechanism for stacking and moving flexible articles as claimed inclaim 1 wherein said means for conveying and moving said stack comprisesan intermittently moving pushing element for moving a newly formed stackto said second station.
 4. A mechanism for stacking and moving flexiblearticles as claimed in claim 2 wherein said means for conveying andmoving said stack comprises an intermittently moving pushing element formoving a newly formed stack to said second station.
 5. A mechanism forstacking and moving flexible articles as claimed in claim 1 wherein saidmeans for holding the articles along their side edges comprises aplurality of flexible fingers directed inwardly toward and engaging bothside edges of the articles forming the stacks.
 6. A mechanism forstacking and moving flexible articles comprising the combination of: a.means for continuously conveying articles in single file order, b. meansfor receiving successive articles from said conveying means and formingsaid articles into a stack of superposed articles at a stacking station,c. means for holding the articles along their side edges to maintainthem in their upright position and to prevent twisting of the articlesas they are being formed into a stack while simultaneously being removedfrom said stack forming means, d. means for removing said stack fromsaid stacking station after the stack contains a predetermined number ofarticles, e. said removing means including means for conveying andmoving said stack of articles from the stacking station to a secondstation.
 7. A mechanism for stacking and moving flexible articles asclaimed in claim 6 wherein said means for receiving successive articlesand forming said articles into a stack comprises a pad wheel having aplurality of spaced arcuate slots on its periphery, means for depositingarticles into the slots thereof and a stripper plate for intercepting aleading edge of each article while supported in a slot to remove thearticles from said slots and form a stack of superposed articles on saidstripper plate.
 8. A mechanism for stacking and moving flexible articlesas claimed in claim 6 wherein said means for conveying and moving saidstack comprises an intermittently moving pushing element for moving anewly formed stack to said second station.
 9. A mechanism for stackingand moving flexible articles as claimed in claim 7 wherein said meansfor conveying and moving said stack comprises an intermittently movingpushing element for moving a newly formed stack to said second station.10. A mechanism for stacking and moving flexible articles as claimed inclaim 6 wherein said means for holding the articles along their sideedges comprises a plurality of flexible fingers directed inwardly towardand engaging both side edges of the articles forming the stacks.
 11. Amechanism for stacking and moving flexible articles comprising thecombination of: a. means for forming a plurality of articles into astack containing a predetermined number of superposed articles, b. meansfor conveying and moving said stack from a stacking station to a secondstation, and c. means for controlling the completed stack duringmovement by said conveying and moving means to prevent dislodgement andmisalignment of any articles in said stack during movement, saidcontrolling means being actuated synchronously with said conveying andmoving means, said controlling means comprising an intermittently movingstack controller arm having a forwardly projecting pad for engaging theforemost article in the stack during movement thereof to said secondstation thereby preventing dislodgement and misalighment of any articlesin said stack during movement thereof.
 12. A mechanism for stacking andmoving flexible articles as claimed in claim 11 wherein said stackforming means comprises a pad wheel having a plurality of spaced arcuateslots on its periphery, means for depositing articles into the slotsthereof and a stripper plate for intercepting a leading edge of eacharticle while supported in a slot to remove the articles from said slotsand form a stack of superposed articles on said stripper plate.
 13. Amechanism for stacking and moving flexible articles as claimed in claim11 wherein said means for conveying and moving said stack comprises anintermittently moving pushing element for moving a newly formed stack tosaid second station.
 14. A mechanism for stacking and moving flexiblearticles as claimed in claim 12 wherein said means for conveying andmoving said stack comprises an intermittently moving pushing element formoving a newly formed stack to said second station.